CN111647838B - Method for spraying abradable coating on annular member with uneven wall surface - Google Patents
Method for spraying abradable coating on annular member with uneven wall surface Download PDFInfo
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- CN111647838B CN111647838B CN202010622394.XA CN202010622394A CN111647838B CN 111647838 B CN111647838 B CN 111647838B CN 202010622394 A CN202010622394 A CN 202010622394A CN 111647838 B CN111647838 B CN 111647838B
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
Abstract
The invention provides a method for spraying an abradable coating on an annular inner wall with an uneven wall surface, which comprises the following steps: (1) providing an annular inner wall to be sprayed; (2) providing a thermal spray gun; (3) positioning the flame flow nozzle and the powder nozzle; (4) firstly, relatively rotating the annular inner wall relative to a thermal spraying spray gun in a first direction, setting the position of a powder nozzle, starting the thermal spraying spray gun to spray the annular inner wall, and suspending spraying when the increment of the thickness of the coating is 0.2-0.5 mm; and relatively rotating the annular inner wall relative to the thermal spraying spray gun in a second direction, setting the position of the powder nozzle, starting the thermal spraying spray gun to spray the annular inner wall, and suspending spraying when the increment of the thickness of the coating is 0.2-0.5 mm.
Description
Technical Field
The invention relates to the field of thermal spraying, in particular to a method for spraying an abradable coating of a ring piece with an uneven wall surface.
Background
Seal coatings, also known as gap control coatings or seal coatings, are coatings used to control the running clearances of mechanical parts. The abradable seal coating is a soft coating that is sprayed on the stator that mates with the rotating component to allow abrasion. Can be prepared by thermal spraying (such as plasma spraying and flame spraying).
The abradable seal coating generally includes a carcass component and an abradable component. The skeletal component may be a metal or ceramic. The abradable component may be selected from one or more of graphite, boron nitride and polyphenyl esters. The abradable seal coating may be composed of aluminum silicon-polyester, aluminum-boron nitride, aluminum-graphite, aluminum bronze-polyester, copper aluminum-boron nitride, nickel-graphite, nickel copper-boron nitride, nickel copper aluminum-boron nitride, nickel chromium aluminum-bentonite, nickel chromium iron aluminum-boron nitride, nickel-diatomaceous earth, nickel chromium aluminum-diatomaceous earth, and the like.
Disclosure of Invention
The inventors have found that in production practice, some parts have an annular inner wall with an uneven surface. Irregular structures such as convex nails, threads, grids and the like exist on the surface of the uneven inner wall, and the irregular structures are provided with surfaces (small-angle surfaces for short) with small included angles (less than or equal to 20 degrees) with the spraying direction. When the abradable coating is sprayed on the uneven wall surface, the spraying flame flow has weak impact force on the small-angle surfaces, the formed coating has insufficient bonding force with the substrate, and the coating tissue is loose and easy to fall off. As the thickness of the abradable coating is continuously increased, loose and shed tissues are continuously accumulated, and finally, a 'cavity' defect is formed near a small-angle surface. Meanwhile, the components of the abradable coating material have large density difference and are easy to be deviated, and the light components are easy to scatter, so that the defects of 'cavities' can be further enlarged. The defective tissues of the cavities are loose, so that the cavities fall off when the coating is subsequently machined, and the cavities are easy to oxidize and lose efficacy under the high-temperature service of the engine, thereby having adverse effects on the operation safety of the aircraft engine.
In order to solve the above problems, the inventors have made extensive efforts to propose an innovative abradable coating spraying method.
In some aspects, the present disclosure provides a method of spraying an abradable coating on an annular inner wall having an uneven wall surface, comprising:
(1) providing an annular inner wall to be sprayed, and determining a circular plane in a space formed by enclosing the annular inner wall, wherein the circular plane is vertical to the axis of the annular inner wall, the circle center O of the circular plane is positioned on the axis, and the radius of the circular plane is equal to that of the annular inner wall;
(2) providing a thermal spray gun comprising a flame stream nozzle for ejecting a flame stream and a powder nozzle disposed adjacent the flame stream nozzle for ejecting an abradable coating powder into the flame stream;
wherein the abradable coating powder comprises agglomerated secondary particles, each agglomerated secondary particle comprising a backbone component and an abradable component, and optionally, a binder;
(3) the flame stream nozzle and the powder nozzle are positioned so as to satisfy the following conditions i) to iv):
i) the flame flow nozzle and the powder nozzle are positioned on the plane determined in the step (1) and are fixed relative to each other;
ii) the jet direction of the flame stream nozzles is perpendicular to the annular inner wall;
iii) the powder feeding angle of the powder nozzle is 5-20 degrees, wherein the powder feeding angle is an included angle between the spraying direction of the powder nozzle and the vertical direction of the flame flow spraying direction;
iv) setting the position of the powder nozzle according to the following rule: positioning the powder nozzle on a counterclockwise side of the flame flow nozzle when the annular inner wall rotates clockwise relative to the thermal spray gun and positioning the powder nozzle on a clockwise side of the flame flow nozzle when the annular inner wall rotates counterclockwise relative to the thermal spray gun;
(4) firstly, enabling the annular inner wall to relatively rotate in a first direction relative to the thermal spraying spray gun, setting the position of the powder nozzle according to the rule of the step (3), starting the thermal spraying spray gun to spray the annular inner wall, and suspending spraying when the increment of the thickness of the coating is 0.2-0.5 m (for example, 0.3 mm); enabling the annular inner wall to relatively rotate in a second direction relative to the thermal spraying spray gun, setting the position of the powder nozzle according to the rule of the step 3), starting the thermal spraying spray gun to spray the annular inner wall, and suspending spraying when the increment of the thickness of the coating is 0.2-0.5 mm (for example, 0.3 mm);
wherein the first direction is selected from a clockwise direction or a counterclockwise direction, and the second direction is opposite to the first direction;
and (5) repeating the step (4) until the abradable coating reaches a preset thickness.
The method adopts the following key innovative characteristic combination to solve the technical problem of the invention:
1. the powder spray gun delivers powder at one side and the installation direction of the powder spray gun is opposite to the rotation direction of the annular inner wall
In the traditional thermal spraying process, the powder feeding mode of the powder spray gun generally adopts a symmetrical double-powder-nozzle powder feeding mode, namely two powder nozzles are arranged on the left side and the right side of a flame stream nozzle.
The invention adopts an innovative unilateral powder feeding process, and the powder nozzle is arranged on one side of the flame flow nozzle opposite to the rotating direction of the annular inner wall. The technical personnel of the invention find that the installation mode can ensure that the powder particles after being heated/accelerated by the spraying flame flow can obtain a certain angle (about 5-10 degrees) of spraying inclination angle, thereby increasing the impact angle of the powder and the small-angle spraying surface of the special-shaped structure, and the installation position of the powder nozzle is opposite to the rotation direction of a workpiece, and the spraying flame flow impacts the small-angle surface in a head-on manner, thereby effectively improving the bonding strength of the coating on the small-angle surface.
2. The powder feeding angle is controlled to be 5-20 degrees.
It is critical to control the powder feed angle at 5 to 20, which allows a certain spray inclination angle to be achieved without affecting the heating and acceleration of the powder material by the spray flame flow. When the powder feeding angle is too small, the powder material is not sufficiently melted, and when the powder feeding angle is too large, the ejection inclination angle cannot be effectively obtained.
3. Bidirectional rotation of annular inner wall
When spraying a certain coating thickness (such as 0.2-0.5 mm), the rotating direction of the annular inner wall is reversed, the mounting position of the powder nozzle is changed, and then a certain coating thickness (such as 0.2-0.5 mm) is sprayed. Thus, the accumulation of potential spraying defects on one side of the workpiece can be prevented, so that the defects of 'cavities' can be eliminated, and the satisfactory coating quality can be obtained.
4. Agglomerated spray powder is used.
The agglomerated spray powder can fix the low-density component abradable component and the high-density component skeleton component in a composite particle, thereby increasing the impact kinetic energy of the low-density component and improving the bonding strength of the spray material on a small angle surface.
The technical problem is solved through the combination of the key innovation characteristics 1-4, so that when the wearable coating is thermally sprayed on the inner wall of the annular piece with the uneven inner wall surface by the spraying method, the coating is compact, the defect of 'cavities' is avoided, and the technical effect is unexpected.
In some embodiments, the spacing between the flame stream nozzles and the powder nozzles is 5 to 10mm (e.g., 6mm), with spacing being in a direction perpendicular to the direction of flame stream ejection.
In some embodiments, the distance from the powder nozzle to the annular inner wall is substantially the same as the distance from the flame flow nozzle to the annular inner wall. For example in the range of ± 10 mm.
In some embodiments, the spray parameters of the flame flow nozzle include: the flow of argon is 40-60 lpm, the flow of hydrogen is 5-7 lpm, the current is 360-400A, the voltage is 65-70 kW, and the spraying distance is 100-140 mm; the spray parameters of the powder nozzle include: the powder feeding speed is 40-50 g/min, and the powder feeding gas flow is 4-5 lpm.
In some embodiments, the annular inner wall and lance combination are moved relative to each other in the axial direction during the spraying process.
In some embodiments, the matrix component may contain a metal powder or a ceramic powder.
In some embodiments, the abradable component contains one or more selected from graphite, boron nitride, and polyphenyl esters.
In some embodiments, the composition of the abradable coating paint may be aluminum silicon-polyester, aluminum-boron nitride, aluminum-graphite, aluminum bronze-polyester, copper aluminum-boron nitride, nickel-graphite, nickel copper-boron nitride, nickel copper aluminum-boron nitride, nickel chromium aluminum-bentonite, nickel chromium iron aluminum-boron nitride, nickel-diatomaceous earth, nickel chromium aluminum-diatomaceous earth, or nickel chromium aluminum yttrium-polyphenyl ester.
In some embodiments, the skeletal component is a metal powder, such as a nickel-containing alloy powder, such as a nickel-chromium-aluminum-yttrium alloy powder, such as a Ni-25Cr-5Al-0.5Y alloy powder.
In some embodiments, the abradable component is a resin powder, such as a polyester powder, for example an aromatic polyester powder, such as a polybenzoate powder.
In some embodiments, the abradable coating powder includes from 60 to 90 wt.% (e.g., from 70 to 80 wt.%) skeletal component and from 10 to 40 wt.% (e.g., from 20 to 30 wt.%) abradable component.
In some embodiments, the abradable coating powder includes 60 to 90 wt% skeletal component, 10 to 40 wt% abradable component, and 0 to 8 wt% (e.g., 1 to 3 wt%) binder.
In some embodiments, the abradable coating powder has a particle size range of-140 mesh to +400 mesh. That is, the powder passed through a 140 mesh screen and failed to pass through a 400 mesh screen.
In some embodiments, greater than 90% by weight of the abradable coating powder is secondary particles, for example 100% by weight is secondary particles.
In some embodiments, the abradable coating powder is prepared using an agglomeration granulation process.
In some embodiments, the abradable coating is sprayed to a thickness of 1mm or more, such as 1 to 3 mm.
In some embodiments, an annular inner wall having an uneven wall surface means that the surface of the annular inner wall has a convex portion or a concave portion. The height of the protrusion part is more than 0.5mm, such as 0.5-2 mm, and the depth of the concave of the groove part is more than 0.5mm, such as 0.5-2 mm. The cross-sectional diameter of the protrusion or the groove may be 0.2 to 1mm, for example, 0.3 to 0.5 mm.
In some embodiments, the thermal spray gun is a flame spray gun or a plasma spray gun.
In some embodiments, the radius of the annular inner wall is greater than or equal to 250mm, such as 200-1000 mm.
In some embodiments, the first direction is clockwise and the second direction is counter-clockwise.
In some embodiments, the first direction is counter-clockwise and the second direction is clockwise.
In some embodiments, the present disclosure provides a component having an annular inner wall, the surface of the annular inner wall being sprayed with an abradable coating, the abradable coating being sprayed by the method of any of the above.
In some embodiments, the spray gun assembly rotates relative to the annular inner wall while the annular inner wall remains stationary during spraying.
In some embodiments, each thermal spray gun includes only one flame stream nozzle and only one powder nozzle.
In some embodiments, the plasma spray system includes a spray power supply, a spray gun, a control device, a gas supply system, a powder feeding device, and a cooling water supply device.
In some embodiments, the powder nozzles are located a distance from the annular inner wall that is substantially equal to (+/-10 mm) the distance of the flame stream nozzles from the annular inner wall.
In some embodiments, the powder nozzle is spaced from the annular inner wall by a distance of 80 to 120 mm.
In some embodiments, the spray distance is less than the radius of the annular inner wall.
In some embodiments, the annular inner wall and lance combination undergo relative movement in the direction of the axis during spraying. Based on this, can fully cover annular inner wall axis direction treat the spraying face.
In some embodiments, the coating material sprayed by the thermal spray gun is an abradable coating material comprising a backbone component and an abradable component.
In some embodiments, the thermal spray gun is a flame spray gun or a plasma spray gun.
In some embodiments, the radius of the annular inner wall is greater than 250mm, such as greater than or equal to 500mm, such as 250-1000 mm.
In some embodiments, the annular inner wall has an aspect ratio greater than 0.1, such as greater than 0.5, such as greater than 1. The aspect ratio refers to the ratio of the length to the diameter of the annular inner wall. The length of the annular inner wall is the dimension parallel to the central axis.
In some embodiments, the annular inner wall is substantially perpendicular to the ground surface during spraying. For example, the annular inner wall may be angled at 90 + -10 deg., such as 90 + -5 deg., such as 90 deg., to the ground.
In some embodiments,% refers to wt%.
In some aspects, a component is provided having an annular inner wall, the surface of the annular inner wall being sprayed with an abradable coating, the abradable coating being sprayed by a method of any of the present disclosure.
In some embodiments, the spray direction of the spray gun is substantially perpendicular to the spray face, e.g., at an angle of 90 ± 10 °, e.g., 90 ± 5 °, e.g., 90 ° to the spray face.
In some embodiments, the annular inner wall is made of metal.
In some embodiments, the abradable coating has a thickness of 1 to 3mm, such as 1.5 to 2.5 mm.
In some embodiments, a base coating is sprayed on the annular inner wall surface prior to spraying the abradable coating. The composition of the base coating is primarily metal. The function of the substrate coating may be to improve the corrosion resistance of the substrate, to improve the bonding force of the abradable coating to the substrate, etc.
Description of the terms
The annular inner wall is a wall surface which is round in cross section and surrounds the circumference, the wall surface can enclose a cylindrical or truncated cone-shaped space, and the central axis of the cylindrical or truncated cone is the central axis of the annular inner wall.
By "the annular inner wall rotates" is meant that the annular inner wall spins about its central axis.
The "clockwise side" and the "counterclockwise side" refer to a side rotating clockwise and a side rotating counterclockwise with the central axis of the annular inner wall as the axial direction, respectively.
The uneven wall surface is relative to the flat surface, compared with the flat surface, the uneven wall surface has special-shaped structures such as convex nails, threads, grids and the like, and the special-shaped structures have small-angle surfaces with a small included angle (less than or equal to 20 degrees) with the spraying direction. The special-shaped structure forms a protruding part or a groove part on the surface of the annular inner wall, the height of the protruding part can be more than 0.5mm, such as 0.5-2 mm, and the depth of the groove part can be more than 0.5mm, such as 0.5-2 mm.
"flame blasting" means melting a spray material (wire or powder) by the high temperature of a gas combustion flame and spraying it onto the surface of a workpiece with a compressed air flow to form a coating.
"plasma spraying" means that a nozzle is used to spray a plasma flame stream, metal or nonmetal powder is fed into the plasma flame stream through a carrier gas, heated to a molten or semi-molten state, and sprayed and deposited with the high-speed plasma flame stream onto the surface of a pretreated substrate to form a coating.
The "spray gun" is a thermal spray gun, and in particular embodiments may be a plasma spray gun.
"spray distance" is understood to mean the distance of the flame stream nozzle from the spray surface.
"spray direction" refers to the direction from the nozzle to the point of spray landing.
"Primary particles" refers to unagglomerated powder particles.
"secondary particles" refers to agglomerated particles formed by the agglomeration of a plurality of primary particles.
"included angle" refers to an acute included angle.
"comprising" may mean a content of more than zero, for example more than 10%, for example more than 20%, for example more than 30%, for example more than 40%, for example more than 50%, for example more than 60%, for example more than 70%, for example more than 80%, for example more than 90%, for example 100%. When the content is 100%, the meaning of "containing" is equivalent to "consisting of …".
Advantageous effects
The disclosed methods or products have one or more of the following advantages:
(1) the spraying method is used for spraying the annular inner wall with uneven wall surfaces, and the obtained abradable coating has compact structure and no gap defect;
(2) the spraying method is relatively simple and has strong operability;
(3) the spraying method has low cost.
Drawings
FIG. 1 shows a nickel-base alloy ring member with uneven wall surface;
FIG. 2 is a schematic diagram of an embodiment of an abradable coating sprayed on the inner wall of an annular member;
FIG. 3 is a partial schematic view of an embodiment of an abradable coating sprayed on the inner wall of an annular member;
FIG. 4 is a schematic illustration of a coating formation process when spray coating the inner annular wall using a comparative example method;
FIG. 5 is a scanning electron micrograph of a cross section of the coating of example 1;
fig. 6 is a scanning electron microscope photograph of a cross section of the coating of comparative example 1.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to examples, but those skilled in the art will appreciate that the following examples are only illustrative of the present invention and should not be construed as limiting the scope of the present invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products commercially available.
Fig. 1 shows an annular element 10 to be coated with a nickel-based alloy. The annular member 10 has a diameter of 580mm, a height of 25mm and a thickness of 5.5 mm. The annular member 10 has an annular inner wall 110, the annular inner wall 110 having a central axis 15, the annular inner wall 110 having a radius of 284.5 mm. The annular inner wall 110 has an uneven surface, and a plurality of protruding pins 112 are distributed on the inner wall surface, wherein the protruding height of the protruding pins 112 is 1.4mm, and the average diameter of the protruding pins is 0.4 mm.
Figure 2 shows a schematic of the spray coating of an abradable coating on the annular inner wall of an annular member. Figure 3 shows a partial schematic view of the spray coating of an abradable coating on the annular inner wall of an annular member.
As shown in fig. 1-3, the step of spraying an abradable coating on the annular inner wall includes:
a circular plane 111 is defined in a space enclosed by the annular inner wall 110, the circular plane 111 is perpendicular to the central axis 15 of the annular inner wall, the center O of the circular plane is located on the central axis 15, and the radius R of the circular plane is equal to the radius of the annular inner wall.
A thermal spray gun 3 is provided, and the thermal spray gun 3 is located in the space enclosed by the annular inner wall 110 and on the circular plane 111. The thermal spray gun 3 includes a flame stream nozzle 31 for spraying a flame stream 33, and a powder nozzle 32 disposed beside the flame stream nozzle 31 for spraying an abradable coating powder into the flame stream 33;
specifically, the inner wall 110 of the titanium alloy ring 10 described above is sprayed with an abradable coating by the following steps.
1. Surface preparation
Cleaning with alcohol to remove oil, protecting a non-spraying surface with a high-temperature adhesive tape, and carrying out sand blasting and coarsening on the surface to be sprayed of the annular inner wall 110 by adopting 60-mesh alumina gravel, wherein the sand blasting pressure is 0.2 MPa. The treated annular member 10 is mounted on a spray turntable with the annular inner wall 110 perpendicular to the ground.
2. Bottom layer spray coating (alloy coating)
Nickel-chromium-aluminum-yttrium alloy powder (KF-308, trademark) is used as bottom coating powder. The specific component of the alloy powder is Ni-25Cr-5 Al-0.5Y.
The primer coating was carried out using a GTV-F6 atmospheric plasma spray system. The spray gun is an F6 plasma spray gun. In the step, the spray gun comprises a plasma flame flow nozzle and two powder nozzles, wherein flame flow is sprayed to the annular inner wall by the flame flow nozzles, and the spraying direction of the flame flow is perpendicular to the annular inner wall. The two powder nozzles are respectively arranged on the clockwise side and the anticlockwise side of the flame flow nozzle, and the powder nozzles spray alloy coating powder to the flame flow. The flame flow nozzle and the powder nozzle are both arranged on the circular plane 111.
The spray turret is rotated to rotate the annular inner wall 110 counterclockwise relative to the spray gun and to move the thermal spray gun up and down in the direction of the axis 15 for spraying. The flame stream nozzle spray parameters were: argon flow 45lpm, hydrogen flow 6lpm, current 550A, voltage 67.5kW, and spraying distance 105 mm. The spray parameters of the powder nozzle were: the powder feeding rate is 45g/min, and the powder feeding gas flow is 4.5 lpm. The spraying thickness of the bottom layer is 0.12 mm.
3. Top coat spray (abradable coating):
the abradable coating was sprayed using a GTV-F6 atmospheric plasma spray system. The coating powder for the abradable coating was a nickel-chromium-aluminum-yttrium polyphenyl ester powder (KF-118, trademark, Beijing mining and metallurgy science and technology group Co., Ltd.). The coating powder is agglomerated powder, and the main components of the coating powder are secondary particles formed by agglomeration of nickel-chromium-aluminum-yttrium powder, polyphenyl ester powder and a binder. The powder comprises 90% Ni-25Cr-5Al-0.5Y, 8% polyphenyl ester and 2% PVP binder.
As shown in fig. 2 to 3, the step of spraying the abradable coating includes:
i) providing a thermal spray gun 3(GTV F6 plasma spray gun), the thermal spray gun 3 including a flame jet nozzle 31 and a powder nozzle 32 (nozzle diameter 1.8 mm);
ii) positioning the flame flow nozzle 31 and the powder nozzle 32 such that the flame flow nozzle 31 and the powder nozzle 32 are both located on the circular plane 111 and are fixed in position relative to each other; the flame flow nozzle 31 forms a drop point T on the edge of the circular plane, the OT direction is the flame flow jet direction, and the jet direction of the flame flow nozzle 31 is vertical to the annular inner wall 110; the powder nozzle 32 sprays abradable coating powder 34 toward the flame stream 33;
iii) the powder nozzle 32 was first disposed on the clockwise side of the flame flow nozzle 31, the distance between the powder nozzle 32 and the flame flow nozzle 31 (the distance is a dimension perpendicular to the ejection direction of the flame flow nozzle 31) was adjusted to 6mm, and the powder feeding angle θ of the powder nozzle 32 was adjusted to 10 ° (the powder feeding angle θ is an angle between the ejection direction of the powder nozzle 32 and the perpendicular direction of the flame flow ejection direction < OT >). The annular inner wall 110 is rotated counterclockwise relative to the spray gun 3 at a rotation speed of 40rpm, and the spray gun is moved up and down along the axis 15 to perform spraying at a gun speed of 2mm/s, the spraying is repeated 1 time each time the spray gun moves up and down, and the spraying is suspended after 10 times of spraying. And then the powder nozzle 32 is replaced to the anticlockwise side of the flame flow nozzle 31, the distance between the powder nozzle 32 and the flame flow nozzle 31 is adjusted to be 6mm, the powder feeding angle theta is adjusted to be 10 degrees, the annular inner wall 110 rotates clockwise relative to the spray gun 3 at the rotating speed of 40rpm, the spray gun moves up and down along the direction of the axis 15 for spraying, the gun moving speed is 2mm/s, the spray gun moves up and down for 1 time, and the spraying is suspended after 10 times of spraying. The increase in coating thickness was 0.3mm per 10 spray passes.
In the step, the spraying parameters of the flame flow nozzle are as follows: the flow rate of argon is 50lpm, the flow rate of hydrogen is 6lpm, the current is 380A, the voltage is 67kW, and the spraying distance is 120 mm; the spray parameters of the powder nozzle were: the powder feeding rate is 45g/min, and the powder feeding gas flow is 4.5 lpm.
iv) repeating step iii) for a plurality of times until the thickness of the surface layer reaches 1.9mm, and stopping spraying.
Comparative example 1:
comparative example 1 differs from example 1 only in step iii), iii) in comparative example 1 comprising:
powder nozzles having a diameter of 1.8mm were installed on both the clockwise and counterclockwise sides of the flame stream nozzle, and the powder nozzles sprayed the coating powder toward the flame stream. The distance between the powder nozzle and the flame flow nozzle was adjusted to 6mm, and the powder feeding angle θ of the powder nozzle was adjusted to 10 °. Rotating the annular inner wall counterclockwise relative to the spray gun at a rotation speed of 40 rpm; and meanwhile, the spray gun moves up and down along the direction of the axis 15 for spraying, the speed of the spray gun is 2mm/s, and the spraying is stopped until the thickness of the surface layer reaches 1.9 mm.
In the step, the spraying parameters of the flame flow nozzle are as follows: the flow rate of argon is 50lpm, the flow rate of hydrogen is 6lpm, the current is 380A, the voltage is 67kW, and the spraying distance is 120 mm. The spray parameters of the powder nozzle were: the powder feeding rate is 45g/min, and the powder feeding gas flow is 4.5 lpm.
Analytical testing
FIG. 3 is a partial schematic view of the inner wall of the annular member sprayed with an abradable coating in example 1. As shown in fig. 3, the surface of the annular inner wall 110 is provided with a protruding spike 112 having a small sprayed surface 114. The direction of rotation of the annular inner wall 110 is counterclockwise as indicated by the first arrow 15. The flame flow 33 is directed perpendicular to the annular inner wall 110 as indicated by the second arrow 35. Example 1 an innovative single-sided powder feeding process was used and the powder nozzle 32 was mounted in the opposite direction to the direction of rotation of the annular inner wall 110, i.e. the powder nozzle 32 was positioned on the clockwise side of the flame stream nozzle 31. By adopting the installation mode, the particles of the coating powder 34 heated/accelerated by the spraying flame flow 33 can obtain a certain angle (about 5-10 degrees) of spraying inclination angle, so that the impact angle of the powder and the small-angle spraying surface 114 is increased, in addition, the installation position of the powder nozzle 32 is opposite to the rotation direction of the workpiece, the spraying flame flow impacts the small-angle spraying surface 114 in a head-on manner, and the bonding strength of the coating on the small-angle surface can be effectively improved.
Fig. 4 (I) to (III) show schematic diagrams of coating formation when the annular inner wall is sprayed using the method of comparative example 1. As shown in fig. 4 (I) to (III), the surface of the annular inner wall 110 is provided with a stud 112. The coating 40 is gradually deposited and thickened on the surface of the annular inner wall 110. The direction of rotation of the annular inner wall 110 is shown by the first arrow 15, which is counterclockwise, and the direction of flame flow is shown by the second arrow 35, which is perpendicular to the annular inner wall 110. As the thickness of the coating 40 gradually increases, void defects 42 are formed within the coating in the vicinity of the studs 112.
The coating microtopography of example 1 and comparative example 1 was observed using a scanning electron microscope.
FIG. 5 shows a photograph of the cross-sectional structure of the coating of example 1 in the vicinity of the "spikes". The figure shows that the coating has dense tissue and no 'cavity' defect.
FIG. 6 shows a photograph of the cross-sectional structure of the coating of comparative example 1 in the vicinity of the "stud". The figure shows that there are more "cavity" defects in the coating texture.
The experimental data show that the coating obtained by the spraying method disclosed by the invention has a compact structure, no cavity defect, the coating quality is obviously improved, and an unexpected technical effect is really achieved.
While specific embodiments of the invention have been described in detail, those skilled in the art will understand that: various modifications may be made in the details within the teachings of the disclosure, and these variations are within the scope of the invention. The full scope of the invention is given by the appended claims and any equivalents thereof.
Claims (11)
1. A method of applying an abradable coating to an annular inner wall having an uneven wall surface, comprising:
(1) providing an annular inner wall to be sprayed, and determining a circular plane in a space formed by enclosing the annular inner wall, wherein the circular plane is vertical to the axis of the annular inner wall, the circle center O of the circular plane is positioned on the axis, and the radius of the circular plane is equal to that of the annular inner wall;
(2) providing a thermal spray gun comprising a flame flow nozzle for ejecting a flame flow and a powder nozzle disposed adjacent the flame flow nozzle for ejecting an abradable coating powder into the flame flow;
wherein the abradable coating powder comprises agglomerated secondary particles, each agglomerated secondary particle comprising a skeletal component and an abradable component;
(3) the flame stream nozzle and the powder nozzle are positioned so as to satisfy the following conditions i) to iv):
i) the flame flow nozzle and the powder nozzle are positioned on the plane determined in the step (1) and are fixed relative to each other;
ii) the jet direction of the flame stream nozzles is perpendicular to the annular inner wall;
iii) the powder feeding angle of the powder nozzle is 5-20 degrees, wherein the powder feeding angle is an included angle between the spraying direction of the powder nozzle and the vertical direction of the flame flow spraying direction;
iv) setting the position of the powder nozzle according to the following rule: positioning the powder nozzle on a counterclockwise side of the flame flow nozzle when the annular inner wall is rotated clockwise relative to the thermal spray gun and positioning the powder nozzle on a clockwise side of the flame flow nozzle when the annular inner wall is rotated counterclockwise relative to the thermal spray gun;
(4) firstly, enabling the annular inner wall to relatively rotate in a first direction relative to the thermal spraying spray gun, setting the position of the powder nozzle according to the rule of the step (3), starting the thermal spraying spray gun to spray the annular inner wall, and suspending spraying when the increment of the thickness of the coating is 0.2-0.5 mm; enabling the annular inner wall to relatively rotate in a second direction relative to the thermal spraying spray gun, setting the position of the powder nozzle according to the rule of the step 3), starting the thermal spraying spray gun to spray the annular inner wall, and suspending spraying when the increment of the thickness of the coating is 0.2-0.5 mm;
wherein the first direction is selected from a clockwise direction or a counterclockwise direction, and the second direction is opposite to the first direction;
and (5) repeating the step (4) until the abradable coating reaches a preset thickness.
2. The method of claim 1, wherein the distance between the flame stream nozzle and the powder nozzle is 5 to 10mm, and the distance is a distance in a direction perpendicular to the flame stream jetting direction.
3. The method of claim 1, wherein,
the spray parameters of the flame flow nozzle include: the flow of argon is 40-60 lpm, the flow of hydrogen is 5-7 lpm, the current is 360-400A, the voltage is 65-70 kW, and the spraying distance is 100-140 mm;
the spray parameters of the powder nozzle include: the powder feeding speed is 40-50 g/min, and the powder feeding gas flow is 4-5 lpm.
4. The method of claim 1, wherein the annular inner wall and lance combination are moved relative to one another in the axial direction during the spraying process.
5. The method of claim 1, characterized by one or more of the following:
-the skeleton component is a metal powder;
-the abradable component is a resin powder;
-the particle size interval of the abradable coating powder is-140 mesh to +400 mesh;
-said abradable coating powder is prepared by an agglomeration granulation process.
6. The method of claim 1, characterized by one or more of the following:
-the skeleton component is a nichrome-aluminum-yttrium alloy powder;
-said abradable component is a polyphenyl ester powder.
7. The method of claim 1, characterized by one or more of the following:
-the abradable coating has a spray thickness of 1mm or more;
spraying a primer alloy coating on the surface of the annular inner wall in advance before spraying the abradable coating.
8. The method according to claim 1, wherein the annular inner wall having an uneven wall surface is an annular inner wall having a surface with a convex portion or a concave portion.
9. The method of claim 1, the thermal spray gun being a flame spray gun or a plasma spray gun.
10. The method of claim 1, the radius of the annular inner wall being greater than 250 mm.
11. A component having an annular inner wall, the surface of the annular inner wall being sprayed with an abradable coating obtained by spraying according to the method of any one of claims 1 to 10.
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